Plant Manager - Columbia Smithsburg, MD

At Columbia we come to work every day driven by the belief that innovation can transform industries, empower communities, and create a more efficient, sustainable world.

With operations spanning five continents and a commitment to excellence in service and support, our purpose extends beyond engineering advanced equipment. We are pioneering innovation and paving a better tomorrow with factory automation solutions worldwide.

Summary:

The Plant Manager is responsible for leading safe, efficient, and effective manufacturing operations to ensure the on-time delivery of high-quality products that meet customer specifications while optimizing inventory levels and maximizing equipment and workforce productivity. Reporting to the Molds General Manager in Vancouver, this role provides overall leadership and accountability for all aspects of plant operations.

Key areas of responsibility include safety, production, maintenance, equipment and facilities management, purchasing of consumables, supplies, and services, as well as budgeting and human resources management. The position also oversees shipping and receiving, inventory management, production control, and quality assurance to ensure operational excellence throughout the facility.

As a key member of the division leadership team, the Plant Manager collaborates closely with employees, internal departments, suppliers, service providers, and customers to support business objectives and deliver exceptional results. The role is responsible for establishing and implementing both short- and long-term operational goals, developing policies and procedures, monitoring performance, and driving continuous improvement initiatives.

This position champions the implementation of advanced manufacturing processes and best practices to maximize asset utilization, increase production throughput, and improve overall operational efficiency. Equally important, the Plant Manager fosters a positive work environment that enables skilled, motivated employees to perform at their highest potential and contribute to the success of the organization.

The Plant Manager maintains full responsibility for departmental financial performance, including labor and non-labor expenditures, fixed and variable costs, budget management, and achieving annual profitability targets.

Essential Functions:

•  Organize Work and Manage Human Resources (30%)

•  Design, establish and maintain an organizational structure to effectively accomplish business objectives.

•  Develop and maintain accurate job descriptions that identify key job duties and responsibilities for all reporting positions.

•  Analyze department workflow and workers’ job duties to ensure that proper staffing levels and skills are available.

•  Work with divisional, regional and corporate Human Resources to manage the implementation of an effective staffing process designed to identify qualified workers in a timely manner. Participate in the recruiting, screening and hiring processes as appropriate.

•  Support Affirmative Action and EEO policies and practices.

•  Adjust hours of work, priorities and staff assignments to ensure efficient operation based on workload. Monitor overtime.

•  Drive continuous growth of labor productivity

•  Utilize performance management tools such as coaching and performance reviews to provide continuous feedback, identify development needs and objectively measure progress for all direct reports. Recommend compensation changes as appropriate. Ensure that performance management tools are fully implemented throughout the department.

•  Observe and comply with all health, safety and environmental regulations and company policies.

•  Fully support and participate in safety audits, meetings, training and corrective actions.

•  Motivate the workforce through effective communications, both formally and informally, regarding state-of-the-business, YTD results, division performance and key business issues, etc.

•  Manage the implementation of new employee orientation, certification and ongoing training programs designed to ensure appropriate skill levels for all workers.

•  Monitor worker compensation claims and expedite employee’s return to work.

•  Monitor work rules and ensure that discipline is administered in a fair, non-discriminatory and consistent manner.

•  Manage the implementation of programs designed to invite employee participation and to motivate and recognize behavior in support of key business objectives.

•  Manage Equipment, Facilities and Production Processes (25%)

•  Track and analyze equipment performance and downtime.

•  Support Sales’ activities aimed at proactively marketing equipment capabilities.

•  Identify opportunities to improve equipment utilization through continuous process improvement.

•  Continuously improve plant operations in order to optimize material flow through the facility.

•  Manage the upkeep and repair of company property including housekeeping and maintenance of equipment, machinery, grounds and buildings.

•  Develop and implement a long-range preventive and predictive maintenance program in order to ensure high equipment reliability.

•  Ensure tooling is properly maintained.

•  Consult with the General Manager, Department Heads and Controller to establish production standards and cost models.

•  Manage the implementation of Lean Manufacturing principles into all phases of production.

•  Develop and implement improved methods of material handling, processing, and packaging to promote efficiency, quality and reduced costs.

•  Consult with Maintenance personnel related to modification of machines and equipment in order to improve production.

•  Manage the development and implementation of standard operating procedures (SOP) for all equipment and facility-related processes.

•  Participate in the development of capital expenditure justifications for new plant, property and equipment.

•  Review plans and specifications, and coordinate the construction of all new capital projects, while strictly adhering to the plans approved by management.

•  Manage Working Capital and Quality Control  (20%)

•  Ensure compliance with customer quality requirements,

•  Develop product quality inspection procedures

•  Investigate all customer rejects and complaints involving plant operations.

•  Communicate and interact with key external customers and mill representatives.

•  Participate in periodic or special inventory audits and reconcile physical counts.

•  Ensure that warehouse personnel enter accurate cost, time and quality information into the computer system.

•  Reduce inventories, including work in progress, finished goods, production and maintenance supplies.

•  Manage reduction of internal yield losses and scrap rejects.

•  Manage Purchasing Services for Items Including Raw Material and Outside Processing (15%)

•  Manage the preparation of bid and contract proposals and solicit bid quotations from vendors and tradesmen.

•  Manage the analysis and evaluation of bid quotations on the basis of price, specifications, delivery, past experience and other factors.

•  Negotiate, review and sign procurement contracts and coordinate contract compliance.

•  Keep informed of all new developments relative to available resources; make recommendations designed to reduce costs and provide environmentally approved materials and services.

•  Participate with the Purchasing staff in conducting value analysis and product evaluation studies as needed.

•   Manage Administrative Duties (10%)

•  Support corporate initiatives including business process improvement, Flawless Execution (Fe), and single system implementation.

•  Attend division meetings contribute and lead group initiatives as required.

•  Participate in the annual budget planning process and regularly monitor expenditures.

•  Assist in the development of departmental objectives.

•  Develop record keeping procedures and manage appropriate department records in accordance with applicable regulations, policies and standards.

•  Proactively develop and implement a professional development program that includes 40 hours of training annually and incorporates suggestions and recommendations from supervisors and mentors.

•  Perform miscellaneous job-related duties as assigned.

Typical Work:

The Plant Manager provides leadership and direction for all manufacturing operations, including production, maintenance, inventory management, quality assurance, purchasing, shipping, and receiving activities. Daily responsibilities include coaching and developing team members, coordinating with sales and customer service teams regarding production schedules, evaluating operational performance, managing supplier relationships, and ensuring compliance with safety and quality standards.

The Plant Manager regularly reviews key performance indicators, addresses operational challenges, participates in safety inspections, leads continuous improvement initiatives, and ensures achievement of departmental and organizational objectives. The role has authority to stop production activities when necessary to address safety concerns, quality issues, or nonconforming materials.

Division contribution (Profit):

•  Recordable accident rate

•  Loss time injury rate

•  On-time delivery rate

•  Number and type of customer rejects

•  Material yield and internal reject rate

•  Non-conforming material inventory

•  Gross margin dollars per man hour

•  Work in progress and finished goods inventory

•  Equipment capacity utilization (overall equipment efficiency)

•  Production and maintenance supplies and inventory

•  Employee turnover

•  Performance reviews completed on time

•  Operating expense

•  Actual expense results vs. annual budget

Knowledge, Skills and Competencies for Success:

- Strong knowledge of manufacturing operations, machining, welding, and/or steel fabrication processes.

- Knowledge of manufacturing engineering principles and process improvement methodologies.

- Experience implementing Lean Manufacturing and continuous improvement tools.

- Knowledge of inventory management, materials control, production planning, and quality systems.

- Ability to evaluate and improve operational processes, workflows, and business systems.

- Understanding of customer service principles and supplier management practices.

- Familiarity with ISO-based quality management systems.

- Experience managing facility expansion, renovation, and capital improvement projects.

- Strong financial acumen, budgeting, and cost management skills.

- Ability to develop and execute both short-term and long-term strategic plans.

- Effective negotiation and contract management skills.

- Strong analytical, organizational, and problem-solving abilities.

- Excellent verbal, written, and interpersonal communication skills.

- Proven leadership, employee development, and performance management capabilities.

- Ability to build strong teams and foster a positive employee relations environment.

- High energy level, resilience, and a results-oriented mindset.

- Proficiency with ERP systems, Microsoft Office Suite, and manufacturing reporting tools.

Qualifications:

Bachelor’s degree in Business Administration, Engineering or Industrial Management is highly desired.  Minimum 2 year Associate degree and/or 3 years applicable experience in the machining, welding or steel manufacturing business is preferred.

Organizational Responsibility:

Reports to:      General Manager, Molds Vancouver WA

Works with:     Operations staff,  Sales Management, Inside and Field Sales Representatives

Controller Human Resources

As above for other divisions

Columbia Machine offers a full benefits package including medical, dental, vision, prescription drug, life insurance, flexible spending accounts, short and long term disability, 401(k), incentive compensation, paid holidays, paid time off, and tuition reimbursement. Equal Opportunity Employer - Women and Minorities are encouraged to apply. Columbia does participate in E-Verify. Applicants must be legally authorized to work in the United States. The company does not sponsor employment visas or work authorization. To apply for this exciting career opportunity today, please apply online at www.columbiamachine.com

Job Type: Full-time

Benefits:

- 401(k)

- 401(k) matching

- Dental insurance

- Employee assistance program

- Flexible spending account

- Health insurance

- Life insurance

- Paid time off

- Professional development assistance

- Referral program

- Tuition reimbursement

- Vision insurance

Schedule:

- 8 hour shift

- Day shift

- Monday to Friday

Ability to commute/relocate:

- Smithsburg, MD: Reliably commute or planning to relocate before starting work (Required)

Work Location: In person